Device for indicating consumption of consumable electrodes



June l, 1965 c. F. REBHUN DEVICE FOR INDICATING CONSUMPTION OF CONSUMABLE ELECTRODE Filed March 2s, 1964 United States Patent O ce 3 186,51@ EVlfCE lll INDECZTENQ CQNSUMPTEN @il CNSUMABLE ELECERDES Charles F. ltebhun, Natrona heights, Pa., assigner to Allegheny Ludlum Steel Corporation, Breckenridge,

Pa., a corporation of Pennsylvania Mar.. 23, 1964i, Ser. No. 353,794-

ltl Claims. (Cl. :t3-4P) This invention relates generally to consumable electrode melting, and more particularly to a method and device for providing a signal when various conditions occur during consumable electrode melting. ln even more particular aspects, this invention concerns a method and device for providing a signal when the melting of the consumable electrode has progressed to each of several selected stations, or when certain failures occur in the melting of the electrode.

In consumable electrode melting furnaces, an elongated electrode is formed of the metal to be melted and are is struck and maintained between the end of the electrode and a crucible or metal contained therein and in which the melted metal is collected and solidies. The electrode is attached by a clamp to equipment which will adjust the electrode height to maintain the proper arc length. The electrode is normally formed with a smaller diameter stub cast on or welded to one end of the main body of the electrode. The stub is secured by a clamp to an electrode ram disposed to be driven to lower the electrode. When the melting of the main body of the electrode has progressed to the region adjacent the stub, the operator commences a procedure known as hot topping. ln this procedure the melting rate is changed by changing the current and/ or speed of movement of the ram. The melting then progresses preferably to as close to the clamp as possible in order to obtain maximum yield, but not so close as to damage the clamp by heat or actual melting. With most furnaces it is ditllcult to ascertain by observation exactly when the melting has reached the area adjacent the stub where het topping should begin, and also it is diiicult to ascertain when the melting is approaching the clamp closely enough to endanger it. Mechanical devices developed for this purpose have proved more or less unsatisfactory in providing this information.

lt is therefore a principal object of this invention to provide discernible signals when given conditions occur during consumable electrode melting.

A more specific object of this invention is the Jprovision of discernible signals when the melting of a consumable electrode has progressed certain predetermined amounts.

An even more specific object of this invention is to `provide discernible signals during melting of consumable electrodes when the melting of the main body of the electrode has been completed, and also when the melting of the stub is approaching the clamp.

Still a further, more general object of this invention is the provision of a device for attachment to an electrode to be consumably melted, which device will provide signals at selected melting conditions.

Where the stub is Ywelded onto instead of being cast integrally with the main body of the electrode, if the welding is improperly performed the welded region may become weak and susceptible to cracking. lf, during operation this region should crack, as does happen on occasion, the alignment of the electrode is altered, which will tend to cause arcing between the side of the Crucible and the electrode, resulting in damage to the crucible and in improperly melted material. Such a condition in some instances may not be quickly detected with conventional equipment.

3,186,510 Patented June 1, 1965 lt is therefore a further object of this invention to provide a signal during consumable electrode melting when a substantial misalignment of the electrode occurs.

A more limited object of this invention is the provision of a device for attachment to an electrode during consumable melting which will provide a signal if a fracture resulting from misalignment occurs.

These and other objects, together with a fuller understanding of the invention, will become apparent from the following description, when taken in conjunction with the accompanying drawing in which:

The single ligure is a side elevational View, somewhat schematic and partially in section, of a consumable electrode melting furnace embodying the signalling device of this invention.

Referring now to the drawing, the signalling device of this invention is embodied in a consumable electrode melting furnace of any suitable design and which may comprise a furnace housing lil which has a lower shell l2 and an upper shell 14. A crucible 16 is disposed in the lower shell l2 and is secured to the housing by means of bolts 1S which extend through anged portions Ztl, Z2 and 24- of the upper shell, crucible and lower shell, respectively. The Crucible is insulated from the housing by annular rings 26 of electrical insulation through which the bolts i8 also extend. The lower shell l2 serves as a water jacket for maintaining cooling water in the space between the Crucible l and the lower shell l2. A suitable water inlet 28 and outlet 30 are provided.

The upper shell i4 of the housing l0 has a top aperture 32 provided with any suitable sealing means (not shown) and through which a ram 3d is slidably disposed in sealed relation therein. The ram 34 is provided with a clamp 35 at the end thereof which clamps the stub end 38 of the electrode to be consumably melted. In this instance, the stub end 38 of the electrode is welded to the main body lll of the electrode as shown at 42. The current is provided to the electrode from an external electrical source marked generally as V1, with the ram and electrode being maintained negative and the Crucible being maintained positive. A drive mechanism represented by the block 44 is provided externally of the furnace disposed to be operated in response to a suitable control system, represented by the block 46, to move the electrode vertically within the housing. The drive mechanism raises and lowers the electrode to maintain the proper positioning of the electrode relative to the molten metal in the Crucible for effecting an efficient melting operation, the result of which is a general controlled lowering of the electrode as the melting progresses.

The signalling device of this invention includes a reel housing 5u which communicates with and is secured to the upper furnace shell i4. The reel housing has disposed therein a spring biased reel 51 electrically insulated from the housing by insulation 53 and on which a four-strand cable 52 is spooled. The four strands of cable are designated by the reference characters 54A, 54B, 54C and 54D, and are insulated by woven asbestos or glass iibre against both electricity and heat. A terminal block 56 is secured to the ram 3ft and is provided with four junctions (unnumbered) to which the strands 54A, 54B, 54C and 54D are connected, respectively. Extending from each of the junctions are signal wires 60A, 66B, 69C and sul), respectively. The ends of wires @3A and 6GB are welded to the main body 4) of the electrode adjacent the weld 42, and the ends of the wires eiC and 69D are welded to the stub end 38 of the electredeV adjacent the clamp 36. The upper ends of the strands 54A, 54B, 54C and 54D are electrically connected, for example, as through a four-section comarsenic 'Lv mutator 55, and by conductors Sdtll, 543i, dCi and SdDl, respectively, to a circuit for providing the signals during the various operating conditions as will be explained hereafter. The signalling circuit includes signal lamps 62A, 62B, 62C and which are responsive, respectively, to signals controlled by the condition of signal wires e'dA, etlil, ellC and elli). Signal lamp 62A is disposed to be connected between conductors tS-l and ed, and signal lamp 62B is disposed to be connected between conductors ed and 63. Conductors ed, 6e and 68 are connected to secondary coil itl of transformer 72. The signal lamp 62C is disposed to be connected between conductors 743 and 7e', and signal lamp 62D is disposed to be connected between conductors '7e and 7S. The conductors 7d, 7e, and "itl are connected to secondary coil of transformer @2. Conductors 64 and i are connected as by conductor 79 to a contact member on the ram 3d. The signal lamps 62A, 62B, 62C and 62D are connected in series with current-limiting resistors 84A, 8d3, 34C and del), respectively. Rectiers dA, 36B, 35C and 36D are connected to conductors 66, bis, 7e and 7S, respectively. Capacitor 88A is connected between conductor oftand rectifier 86A, capacitor 38B is connected betweenconductor tid and rectifier 35B, capacitor 88C is connected between conductor '74 and rectitier 36C, and capacitor 33D is connected between conductor '7d and rectitier 86D. Normally open manually operated switches MA, WB, 96C and @iiD are disposed to be operated to connect the energizing windings of relays lllZA, H2B, ltilZC and 112D, respectively, to rectiiers 3oz-t, 86B, 36C, and 86D, respectively. Two additional signal lamps l2 and 94 are disposed to be connected through resistors @d and 9S, respectively, between conductors lill) and lili. The conductors Mtl and lltlZ are connected to the secondary coil INM of transformer we. A capacitor le@ is con-v -nected between the conductors ttl@ and 1h92, and a rectier Mtl is provided in conductor loll. The other end of the energizing windings of relays MZA, H2B, lllZC and MZD are connected to conductors d-tAl, fill-Bl, 5dCi and 54H31, respectively. When energized, relay lllZA operates normally open relay Contact lllZAl to establish va holding circuit for relay lllZA. Also, when energized, relay llZA closes normally open relay contact llZAfZ to connect conductor 66 and resistor 84A, and opens normally closed relay contact lllZA to interrupt the energizing circuit for signal lamp 2. When energized, relay H2B operates normally open relay contact M1251 to establish a holding circuit for relay 112B. Also, when energized, relay H2B closes normally open relay contact H2B?, to connect resistor @4B and conductor 63, and opens normally closed relay contact H2133 to interrupt the energizing circuit for lamp 92. When energized, relay MEC operates normally open relay contact frlZCl to establish a holding circuit for relay lrZC. Also, when energized, relay E2C closes normally open relay contact llZCZ to connect resistor llC and conductor 7d, and opens normally closed relay contact i12-C3 to interrupt the energizing circuit for lamp 9st. When energized, relay lllZl) operates normally open relay contact llZDl to establish a holding circuit for relay llZD. Also, when energized, relay ilZD closes normally open relay Contact lllDZ to con* nect resistor 84D to conductor 73, and opens normally closed relay contact lilZD to interrupt the energizing circuit for lamp 94.

The energizing windings of relay lle are connected in parallel with signal lamp 92, and in series with normally closed relay contacts' llZA and MZBS, and the energizing windings of relay llo are connected in parallel with lamp 9d and in series with normally closed relay contacts llllCS and lllZDi. VRelays illitand llo' are provided withA at least one contactmember each (not shown), which contact members are disposed for operation to control the connection of the automatic control te of the drive mechanism 4d. The primary windings Vconductors MAL 54H1,

ot transformers "i2, SZ and ldd are connected to any suitable external voltage source V2.

Operation The stub of the electrode is secured in the clamp 36, and the ends of signal wires @A and edil are connected so as to be generally vertically spaced just below the weld d2, and the ends of wires ed() and etti) are connected so as to be vertically spaced just below the clamp 3f. The melting of the electrode is commenced by impressing the voltage across the electrode and the crucible lr6, which will cause an arc between the crucible and the electrode, causing melting of the electrode; normally the electrode will be maintained negative and the crucible maintained positive. The drive mechanism ll adjusts the positioning of the electrode toV establish a desired arc length as described, and atter melting has commenced the Voltage impressed on the electrode through the clamps 36 and ram 34 will be carried as a signal through wires aller, 6GB, dit() and otlD and terminal blocl; 523, and thence through wires 54A, and 54D, respectively, the four-section commutator 55 and SflCll and 5493i, respectively, to the energizing windings of relays lilZA, llZB, llZC and lllZD, respectively.

A negative voltage is impressed from the ram .3d hrouffl; conductor to wires and 74. Switches QtA, @dC and NPD are then operated manually to closed positions to connect the energizing windings ot relays rIlEA, H2B, lill@ and llZD to the energizing source to effect an operation thereof. When thus energized, MEA operates contact member ll-Al to establish the holding circuit described, after which switch is opened, operates Contact member lllZA. to establisb` the energizing circuit tor signal lamp 62A, and operates contact member rllAI to interrupt the energizing circuit for relay lll/l and signal lamp 92. When contact member ilTtZCll establishes the holding circuit for relay'ttl C and switch 916C is moved to its normallyV opened position, contact member lllZCZ establishes the energizing circuit for lamp e2@ and contact member M253 interrupts the energizing circuit for relay ille and lamp The lighting of lamp 621C indicates wire oilC is connected between the stub l and the terminal 56. Likewise, relay MZD, when energized, moves contact member llEDll to establish the holding circuit for relay lllZD, after which switch @iiD is manually opened, contact member ilDZ to establish the energizing circuit for lamp eil?, and contact member lltZD; to interrupt the energizing circuit tor relay llo and lamp When lighted, lamp 62D indicates that wire del? is connected between the stub 3S and the terminal Se. -Thus, during melting of the electrode, lamps 62A, 62B, 62C and 62D will normally glow, while lamps 92 and @dv/ill not glow. When the melting progresses to the point where the connection between wire @tlf-t and the main body of the electrode is melted, the energizing circuit for relay llfA will be interrupted and relay contacts lllZAll and i2 will be moved to Vtheir.circuit-interrupting positions Contact lllZAS to a circuit-establishing position.'V The opening of contact MEAZ will interrupt the energizing circuit for lamp 62A which then ceases to be lighted. will indicate to the operator that the melting as progressed to point ol contact of the wire 63A on the electrode. As the melting continues, the connection of wire 6GB to the electrode will also be melted to interrupt the energizing circuit of relay 112B, and contacts 112B1 and 112B2 will be opened thus deenergizing lamp 62B, causing it to go out, and Contact 112133 will be closed.

As lamp 62A goes out, this is a visual indication to the operator that melting is rapidly approaching the point where hot topping should begin. When both lamps 62A and 62B have gone out, the operator knows it is time to start the procedure of hot topping (that is, reduce the rate of melting), since the melting has proceeded close to the Vicinity of the weld 42. Further, the closing of both contacts 112A3 and 112B3 completes the circuit for lamp 92, causing lamp 92 to flow and give a positive visual signal to the operator, and this lamp is preferably of a distinctive color such as blue or red which will immediately draw the operators attention, as opposed to the extinguishing of the two lamps 62A and 62B, so that he can manually initiate a change in the operation of the control 46. However, as shown, the closing of contacts 112A3 and 112B3 will energize relay 114, and by suitably connecting relay 114 to the control 46, the controls may be programmed to automatically start hot topping. One skilled in the art will recognize how such programming can be accomplished. As hot topping is continued, either manually or through the automatic controls, and melting of the stub 3S is progressively continued to the connection of wire 66C, the connection of wire ilC is melted. The melting of such connection interrupts the energizing circuit for relay 112C, which is then operated to close contact 112C3 and open contacts 112C1 and 112C2, thus causing lamp 60C to be extinguished, indicating to the operator that the hot topping is nearly completed. As the melting continues, the connection of the wire 60D with the electrode stub is melted and the energizing circuit for relay 112D is interrupted, causing contact 112D?) to close and contacts 112D1 and 112132 to open and lamp 66D to be extinguished, which indicates to the operator that the hot topping has been completed and that further melting will damage the clamp. Since contact 112GB has been previously closed, the closing of Contact 11233 establishes the energizing circuit for relay 116 and lamp 94, causing it to glow. Lamp 94 is also of a contrasting color such as red or blue, and preferably different from lamp 92; this lamp provides an additional positive signal to the operator that hot topping has been completed and that melting should cease to prevent damage to the clamp 36. The operator can manually initiate a change in the operation of control 46 to retract the ram and interrupt the arc, or, yas in the case illustrated, the relay 116 will be operated to effect an automatic change in control 46 to stop the melting operation. One skilled in the art will recognize how such connections can be made.

The wires are used in pairs, ie., Wires StiA and 60B as one pair and wires 60C and 69D as another pair, as a safety or check feature, with the Wires being connected at predetermined positions vertically along the electrode and stub as illustrated so that if there is a malfunction in either of the wires or its associated circuit, the other wire will continue to give a proper indication of the condition.

Also, another benefit that can be derived from this system is an indication of a failure of the weld 42. For such an indication it is -necessary that the wires 60A and 66B be reasonably free of slack. If the weld 42 should fail and the electrode should start to twist or pull down from the stub, the connection of the wires 69A and 60B to the electrode would immediately be broken, which would cause lamps 62A and 62B to go out, and lamp 92 to glow. This would be an immediate indication to the operator that there is a malfunction and that he should take immediate steps to stop the melting and retract the ram and electrode carried thereby. if such an indication were not Agiven and the melting stopped, considerable damage to the Crucible and melt would result.

Although an embodiment of this invention has been shown and described, various adaptations and modifications may be made therein without departing from the scope and appended claims.

I claim:

1. In a consumable electrode melting furnace having an enclosed melting chamber, ram means to advance the electrode being melted downwardly, and clamp means to secure the electrode to the ram means, the improvement which comprises, an electrical circuit disposed externally of said furnace, said circuit having first and second portions each including signalling means having a first condition when the respective portion is energized responsive to an electric signal and a second condition when no signal is received, first and second current-conducting wire means each having a first end connected, respectively, to the first and second portions of said circuit and a second end connectable to said electrode at spaced selectable locations, each of said wire means having a supply length thereof disposed to extend as the ram moves the electrode downwardly, and a source of electricity to provide a flow of signal current through said electrode and each of said first and second wire means to said first and second portions, respectively, of said electrical circuit when said wire means is connected to said electrode, whereby when the electrode is melted in the region of the connections of said first and second wire means the connections will be broken and the signal removed from the respective portions of said electrical circuit, thereby causing the second condition of the signalling means to occur in each portion of the circuit when its respective signal is removed.

2. The combination of claim 1 further characterized by second signalling means and means connected to said first and second portions of said circuit to operate said second signalling means, whereby additional discernible signals are provided when said electrical signals are removed frorn the portions of said circuit.

3. In a consumable electrode melting furnace having an enclosed melting chamber, ram means .to advance the electrode being melted downwardly, and clamp means to secure the electrode to the ram means, the improvement which comprises, an electrical circuit disposed externally of said furnace, said circuit having a first and second portion each including a signal lamp adapted to glow when its respective portion is energized responsive to an electric signal, first and second current-conducting wire means each having a first end connected respectively to the first and second portions of said circuit and a second end connectable to said electrode at spaced selectable locations, each of said wire means having a supply length thereof disposed to extend as the ram moves the electrode downwardly, and a source of electricity to provide a flow of signal current through said electrode and each of said wire means to said electrical circuit when said wire means is connected to said electrode, whereby when the electrode is melted in the region of each connection of the wire means, the connection will be broken and the signal removed from the respective portion of the circuit, thereby causing the respective signal light to be extinguished.

4. In a consumable electrode melting furnace having an enclosed melting chamber, ram means to advance the electrode being melted downwardly, and clamp means to secure the electrode to the ram means, the improvement which comprises, an electrical circuit disposed externally of said furnace, said circuit having first and second portions each including signalling means having a first condition when the respective portion is energized responsive to an electric signal and a second condition when no signal is received, first and second current-conducting wire means each having a first end connected respectively to the first and second portions of said circuit and a second end connectable to said electrode at spaced selectable locations, reel means mounted on said furnace dissero having a supply length of `said wire means spooled thereon and adapted to supply the required length of wire as the electrode is moved downwardly, and a source of electricity to supply a iiow of signal current through said electrode and each of said wire means to said electrical circuit when said wire means is connected to said circuit, whereby when the electrode is melted in the region of each wire means the connection will be broken and the signal removed from the respective portion of the circuit, thereby causing the second condition of the signal means to occur in each portion of the circuit when its respective signal is removed.

5. The combination of claim dl wherein each of said signalling means includes a lamp adapted to glow when a signal is received in its respective portion of the circuit.

6. The combination of claim 5 further characterized by second signalling means and means connected to said iirst and second portions of said circuit to operate said second signalling means whereby additional discernible signals are provided when said electrical signals are removed from the portions of said circuit.

7. ln a consumable electrode melting furnace having an enclosed melting chamber, ram means t0 advance the electrode being melted downwardly `and clamp means to secure the electrode to the ram means, the improvement which comprises, an electrical circuit disposed externally t said furnace, said circuit having rst and second portions each including signalling means having a first condition wnen the respective portion is energized responsive to an electric signal and a second condition when no signal is received, a terminal block mounted on said ram means and having a pair of electrical connections, a first pair of wires each having one end connected to one of said electrical connections on said terminal bloclr and the other end connected to one of said portions of said circuit, said iirst pair of wires having a supply length disposed to extend as the ram moves the electrode downwardly, a second pair of wires each having one end connected to each of said spaced connections of said terminal block and the other ends being connectable to said electrode at spaced locations thereon, a source of electricity to provide a flow of current through said electrode and said wires to said circuit when the wire means are connected to the electrode, whereby when the electrode is melted in the region of the connection of each of the wire means to the electrode, the connection will be broken and the signal removed from the respective portion of the circuit, thereby causing the second condition of the signalling means to occur in each portion of the circuit when its respective signal is removed.

The combination of claim 7 wherein said signalling means includes lamps adapted to glow when energized by a current in its respective portion of the circuit.

9. rl`he combination of claim 8 wherein the supply length of said wire is carried on a reel mounted on the furnace.

MD. The combination of claim 9 further characterized by second signalling means and means connected to said first and second portions of said circuit to operate said second signalling means, whereby additional discernible signals are provided when said electrical signals are removed from the portions of said circuit.

llieierences Cited by the Examiner UNITED SmATES PATENTS 218,375 8/79 Fuller 314-10 501,081 7/93 Kirkegaard S14-10 2,762,856 9/56 Newcomb et a1. 13--9 RCHARD M. WOOD, Primary Exan'zz'ner.

IGSEPH V. TRUI-IE, Examiner. 

1. IN A CONSUMABLE ELECTRODE MELTING FURNACE HAVING AN ENCLOSED MELTING CHAMBER, RAM MEANS TO ADVANCE THE ELECTRODE BEING MELTED DOWNWARDLY, AND CLAMP MEANS TO SECURE THE ELECTRODE TO THE RAM MEANS THE IMPROVEMENT WHICH COMPRISES, AN ELECTRICAL CIRCUIT DISPOSED EXTERNALLY OF SAID FURNACE, SAID CIRCUIT HAVING FIRST AND SECOND PORTIONS EACH INCLUDING SIGNALLING MEANS HAVING A FIRST CONDITION WHEN THE RESPECTIVE PORTION IS ENERGIZED RESPONSIVE TO AN ELECTRIC SIGNAL AND A SECOND CONDITION WHEN NO SIGNAL IS RECEIVED, FIRST AND SECOND CURRENT-CONDUCTING WIRE MEANS EACH HAVING A FIRST END CONNECTED, RESPECTIVELY, TO THE FIRST AND SECOND PORTIONS OF SAID CIRCUIT AND A SECOND END CONNECTABLE TO SAID ELECTRODE AT SPACED SELECTABLE LOCATIONS, EACH OF SAID WIRE MEANS HAVING A SUPPLY LENGTH THEREOF DISPOSED TO EXTEND AS THE RAM MOVES THE ELECTRODES DOWNWARDLY, AND A SOURCE OF ELECTRICITY TO PROVIDE A FLOW OF SIGNAL CURRENT THROUGH SAID ELECTRODE AND EACH OF SAID FIRST 